Stumped by Frankenbike's Caliper

While I still have some silver hair left, I figured I'b better appeal to the experts over here. :woohoo:

We've got a customer with a KZ1000, sort of. It's a bit of a mongrel with some 900 components, some 1000 components, and maybe even a 650 component thrown in just to make me pull my hair out further.

It's sporting a 42mm caliper piston, which is all well and good, but the dust seal is much larger (57mm O.D.) than the seal. This is what's throwing me. Also, the slider pin dust boots are much larger than those found in the kit.

A picture is worth 1000, as they say. Have a look at the images in this link. You'll see our kit components in a side-by-side comparison with the stock components.
Frankenbike's caliper

I've scoured the fiche looking for a piston that's similar to this one - A distinct taper that doesn't look familiar. I've also looked for an oddball caliper with a dustboot part number that is different from the rest of the caliper dust boots 43054-003 from that era. Coming up empty.

If you look at the caliper mount bracket, it has "squared off", or flat, cutouts in the window. This is indicative of a 650. The 1000s have a circular window without the squared off cutouts.

It's also using EBC FA73 brake pads -- found ONLY in the following:
KZ440A 80-82
KZ440K1 / D1-4 80-82
KZ550A1 80
KZ650 C1/C2/C3/D2/E1/F1 77-80
KZ750 G1 80
KZ1000 C2/C3/C4 79-81
Z1000 A3/A3A/A4/B3/B4/D3/G1

It's also noteworthy to mention that the FA33 brake pad is identical except for thickness and were found in earlier models (S2, S3, KH, and earlier KZ650s and 1000s)

Thoughts?

I tried opening the picture link but it's asking for a login.

Later, Doug

X2

Not sure why the problem, try these:

Sorry i cant help u with this 1.
I would like to thank u on behalf of all of the guys u fellows at Z1E, have helped out.
I have not dealt with u personally, but i have always had great service from Z1E.
what i see u doing here speak volumes for your service
Have u tried z1ownersclub.com/forum/1685549/
Thanks
Mark Saunders.

Thanks for the kind words Mark.
Much aprpeciated.
I haven't tried Z1OC yet - I was hoping for divine revelation from this venue first.

I just hate being stumped! And this one has me stumped! Hopefully temporarily!

No eBay APP ID and/or Cert ID defined in Kunena configurationSearch "KZ caliper" on Ebay.

Looks like these:

Any numbers on the parts? Kawasaki sometimes leaves the last 3-4 digit number cast into the parts for identification. Take a top clamp for example, all top clamps start with the same part number 44039. The last part of the part number describes the actual part...it's identifier. So 44039-1234 is a top clamp for one bike and 44039-4567 is a top clap for another bike. So you 'may' find "1234" or "4567" cast into the part. (just using those as an example)

If you find the 3 or 4 digit number, find the prefix (first 5 digits) from some other model, add that to the number cast into the part (along with a hyphen) and google it or search on the Kawasaki parts fiche.

Another trick is to just search Ebay with the prefix. Lets take 44039, top clamp (holder fork upper)

motors.shop.ebay.com/i.html?_from=R40&_t...3&_nkw=44039&_sacat=

Stupid idea but could it possibly be bored?

Good lead.
Not so good outcome.

Knowing that the online microfiche is marginally less than 100% accurate, :ohmy: I checked the old acetate fiche dated Aug.83 (KZ1000-B3) for a possible different dust boot part number. To no avail. The part number referenced was that same 43054-003 previously referenced and shown in the images. Simply too small.

Interestingly though, the piston in the evilbay images has that distinct taper as shown in my file images.

Still baffled.

As far as part numbers, I don't have them in hand and can only communicate via email with our customer.

Thanks KidKawie, apprecaite you.

I was looking at a KH caliper the other day, the same mount spacing as the Z1 caliper and it looked very similar to the on you show in the pic. Have you ruled out a KH caliper?

Maybe the seals were packaged incorrectly.

KH calipers are similar and use the 42mm piston and that same dust boot 43054-003. But the later calipers are cast so they're symetrically able to fit both right and left sides. Simply a matter of drilling the oil / banjo bolt inlet on one side of the bleeder passage or the other. KH's and the earlier calipers (pre-77 I think)didn't have that feature.

Good call, though.